Golf Club Head

ABSTRACT

A golf club head is disclosed. The head has a shell with an inner surface defining a hollow interior portion. The inner surface has a plurality of inwardly extending ribs made of resin and a single continuous filament located in the resin.

RELATED APPLICATIONS

This application is a division of Ser. No. 11/435,653, filed May 17,2006, which is incorporated by reference in its entirety and which ispending as of the filing date of this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to golf club heads, more particularly ofthe composite metal “wood” type, and a method of making golf club heads.

2. Description of the Background and Relevant Information

Wood-type golf club heads traditionally were made from wood, e.g.,persimmon. However, with advances in materials, wood-type golf clubheads are currently predominantly made from high performance metals suchas titanium, and other materials such as fiber-reinforced plastics. Manyclub heads made from fiber resin composite materials are compressionmolded around relatively rigid molding cores. In instances where ahollow interior cavity is desired, dispersible cores made from meltablematerials such as wax or low melting point metals have been employed.

Wood-type club heads made predominantly of metal may be fabricated bywelding or adhesively joining together edges of two or more thinsections of a club head shell made of metal such as stainless steel,beryllium copper, aluminum, titanium, etc., thereby producing aone-piece shell.

For some years now, heads made entirely of a composite material, withthe exception of the sole, have been manufactured. Such types ofconstructions are rarely favored by professional players because theyare most often made of a single element, by the compression moldingmethod, without any particular regard to the distribution of mass.

A head made of a plastic material is disclosed in British PatentPublication No. 2,128,539. This head is made of a single thermoplasticelement injected into a mold around a meltable core. The head thusmanufactured does not allow a good control over the trajectory of theballs because the problem of balancing the club is not resolved.

U.S. Pat. No. 5,000,454 discloses a head made of a reinforced plasticmaterial and comprising an element acting both as the reinforcement ofthe striking face and as the balancing weight. However, such a structuredoes not yet permit the club to be balanced satisfactorily.

U.S. Pat. No. 6,824,636 B2 is directed to a method for the manufactureof a hollow three-dimensional fiber golf club head wherein afluid-removable core shaped in the general form of the golf club head isplaced in a flexible pressurizable bladder surrounding the core. Atleast one ply fiber impregnated with a curable resin is wrapped over thecore and bladder, and a cured part is formed by pressurizing the bladderwhile the core, bladder and impregnated fiber is in a female mold toforce the plies against the inner surface of the mold. After heating tocure the resin, the bladder and the fluid removable core is removed fromthe interior of the cured part by disintegrating the core with a fluidsufficient to allow removal of the bladder. This method is complex anddifficult of reproduction on a commercial scale.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the disadvantagesinherent to the above described and traditional methods and resultingstructures of club heads, and to provide a new head design as well as anew method of manufacturing such head.

Thus, one of the more specific objects of the invention is to provide amanufacturing method enabling a more efficient new head structure to beobtained, especially as regards distribution of mass, durability, andfinishing quality. The method according to the invention is particularlyadapted to the large scale production of elements requiring a minimumnumber of operations to produce what might be considered a complex yethighly advantageous golf club head.

Thus, according to the invention, a method of manufacturing a golf clubis disclosed. The method is comprised of the following steps. A singlecontinuous filament is wound multiple times about a soluble core. Thewound core is then located in a mold. The wound core is then pressurecoated with a resin in the mold. The resin disperses among the filamentwindings. The resin is allowed to cure and form a filament and resinshell about the core. The soluble core is then removed from the shellwhile the continuous filament is retained within the shell.

The shell has an inside surface and an outside surface. The insidesurface defines a substantially hollow interior portion and the insidesurface has a plurality of ribs that extend into the interior portion.The ribs and the shell are substantially comprised of the resin and thesingle continuous filament located within the resin.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description when considered in the light of the accompanyingdrawings in which:

FIG. 1 is a schematic, perspective view of an embodiment of a componentfor use in the method of the present invention;

FIG. 1A depicts a cross-sectional view of a mold for forming thecomponent depicted in FIG. 1;

FIG. 2 is a schematic view of one embodiment of a filament windingmachine and the component of FIG. 1 of the present invention;

FIG. 3 is a schematic, cross-sectional view of one embodiment of a moldfor use in the method of the present invention;

FIG. 4 is a schematic, perspective view of another component of thepresent invention;

FIG. 5 is a schematic, cross section of a preferred embodiment of astructure for creating a shaft-receiving portion in the presentinvention;

FIG. 6 is a schematic, perspective view of one embodiment of the presentinvention;

FIG. 7 is a schematic, perspective view of one embodiment of the presentinvention;

FIG. 8 is a schematic, cut-away view of one embodiment of a club head ofthe invention;

FIG. 9 is a schematic, perspective view of one embodiment of the bottomof a club head of the invention; and

FIG. 10 is a schematic, perspective view of one embodiment of a clubhead produced in accordance with the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It is to be understood that the invention may assume various alternativeorientations and step sequences, except where expressly specified to thecontrary. It is also to be understood that the specific devices andprocesses illustrated in the attached drawings, and described in thefollowing specification are simply exemplary embodiments of invention.Hence, specific dimensions, directions or other physical characteristicsrelating to the embodiments disclosed are not to be considered aslimiting, unless expressly stated otherwise.

Referring to FIG. 1, a preferred embodiment of a golf club head core 20is depicted. The golf club head core 20 is preferably made by theprocess and materials described in U.S. Pat. No. 3,692,551, which isincorporated by reference in its entirety into the presentspecification.

By way of example only, FIG. 1A depicts a preferred embodiment of a mold11 which may be used to form the core 20 depicted in FIG. 1. The mold 11preferably has a first half 12 and a second half 13 which are separablefrom one another. The first half 12 and the second half 13 define aninterior chamber 14 having a substantially similar shape to the shape ofthe core 20. A core front face block 15 is preferably located with theinterior chamber 14. The core front face block 15 has a plurality ofribs 16 extending into the interior chamber 14. The ribs 16 will be usedto form grooves in the front face of the core 20, which are described indetail below.

A plurality of ribs 19 extend into the interior chamber 14 from thefirst half 12 and the second half 13. The ribs 19 will be used to formgrooves in the upper surface of the core 20 and the lower surface of thecore 20, as described below.

Those skilled in the art will appreciate that the core front face block15 may have any design, including any pattern of ribs or shapes tocreate a core 20 having any desired shape.

The mold 11 preferably has at least one sprue 19A for introducing thecore material (not shown) into the interior chamber 14 from outside ofthe mold 11. The mold 11 may have means to heat or cool to solidify thecore material so that the core material conforms to the core front faceblock 15. Alternatively, if the core material does not require heatand/or cooling to set up, then such means are not required. The ribs 16,19 extending into the interior chamber 14 from the core front face block15 form grooves in the core material, discussed below. The heat and/orpressure, if required, exerted by the mold 11 on the core materialcreate a core 20 which, in a preferred embodiment, looks like the core20 depicted in FIG. 1.

Referring to FIG. 1, the core 20 is preferably shaped to have a somewhatcurvilinear front face 26, a curvilinear upper surface 28 and thecurvilinear lower surface 24. In FIG. 1, the core 20 is located upsidedown so that at least two core prints 112 can be clearly seen.

Preferably, an insert 30 is at least partially formed into the core 20about each core print 112. The insert 30, thus, is positioned within thecore 20 when the core 20 is formed as described above. The insert 30 mayhave a first circumferential ring 31A (seen in FIG. 3) which helpssecure the insert 30 in the core 20. The insert 30 also preferably has asecond circumferential ring 31B (seen in FIGS. 1 and 3) which will bereceived within a resin, described in more detail below.

As best seen in FIG. 9, the inserts 30 are preferably cylindrical inshape with a hollow interior portion 30A. The inserts 30 have a threadedinner surface 30B.

The upper surface 28 and the lower surface 24 preferably taper away fromthe front face 26 until they meet at a rearward portion 32 of the core20. Side portions 34 of the upper and lower surfaces 24, 28 alsopreferably taper toward one another. Although a preferred embodiment ofthe upper and lower surfaces 24, 28 is depicted in the figures, thoseskilled in the art will appreciate that the core 20 can be constructedwith any number of surfaces, edges, depressions or curves and have anyshape or size. By way of example only, the upper and lower surfaces 24,28 can taper to a rear surface (not shown), rather than to a roundededge 36. Additionally, the side portions 34 of the upper and lowersurfaces 24, 28 can taper to side surfaces 34, rather than to roundedside edges 38, as shown in FIG. 1.

In the preferred embodiment, a depression 40 in the core 20 is providedadjacent one side of the front face 26. The depression 40 will be usedto form a portion of the finished golf club head that will receive ashaft, as described in more detail below.

Preferably, the at least two core prints 112 extend away in asubstantially perpendicular fashion from the lower surface 24 of thecore 20. Each core print 112 is preferably positioned in an area of thelower surface 24 of the core 20 adjacent one of the side portions 34.The core prints 112 can be positioned in any area on the lower surface24 between the front face 26 and the rearward portion 32 of the core 20.However, in the preferred embodiment, the core prints 112 are closer tothe rearward portion 32 than the front face 26 of the core 20 to lowerthe center of gravity of the finished golf club head.

Referring to FIG. 1, a plurality of grooves 42 is preferably locatedacross the front face 26, the lower surface 24 and the upper surface 28of the core 20. The grooves 42 extend diagonally across the front face26 of the core 20 to intersect one another; however, it is within thescope of the present invention to extend the grooves 42 across the frontface 26 in any orientation, whether intersecting or not. Additionally,although FIG. 1 depicts the grooves 42 continuously extending across theface 26, it is within the scope of the present invention to interruptone or more of the grooves 42, either on the front face 26 of the core20, or in any other area of the core 20. The preferred embodiment of theinvention also locates the grooves 42 at a constant depth in the core20, although variable depths are within the scope of the invention.

In the preferred embodiment, the grooves 42 extend from the front face26 rearward across the lower surface 24 of the core 20 and rearward fromthe front face 26 across the upper surface 28 of the core 20. Althoughthe grooves 42 are depicted as parallel to one another on the lowersurface 24 of the core 20, and they are preferably located parallel toone another on the upper surface 28, it is within the scope of thepresent invention for the grooves 42 to extend in a non-parallel fashionacross the lower surface 24 and the upper surface 28 of the core 20.

As shown in FIG. 2, the above-described core 20 is located in a filamentwinding machine 44, known to those skilled in the art, for winding acontinuous filament 46 about a workpiece. Filament winding machines 44within the scope of the present invention, but which in no way limit thepresent invention, are those made by McClean Anderson of Schofield, Wis.Such machines 44 typically have a supply of filament 48 on at least onespool 50. The spool 50 is preferably moveable via control by a computer(not shown) through multiple axes of rotation with respect to the core20 located in a bit mechanism 52.

The bit mechanism 52 comprises a tapered point 54 on one end forengaging one side portion 34 of the core 20 and a clamp 56 on the otherend for engaging the opposite side portion 34 of the core 20. The clamp56 may be, by way of example, a contoured fit split clamp. Preferably,the bit mechanism 52 is rotated about at least one axis by a motor (notshown) controlled by the same computer to coordinate the rotation of thebit mechanism 52 with the movement of the spool 50.

Machines capable of having a plurality of supplies of filament 48 andwhich are capable of controlling more than one spool 50 tosimultaneously wind a plurality of cores 20 are also within the scope ofthe present invention.

In the preferred embodiment, the filament 46 on the filament windingmachine 44 is a continuous strand of carbon fiber filament. Othercontinuous strands of filament 46, such as Kevlar® manufactured by theE.I. Du Pont Nemours Company of Wilmington, Del., may be used withoutdeparting from the scope of the present invention. Regardless of thecomposition of the filament 46 selected, the filament 46 should havephysical and performance characteristics comparable to carbon fiberfilament or Kevlar® filaments.

The filament-winding machine 44 may also comprise one or more tensioners58 for providing a pre-determined amount of tension to the filament 46.The machine 44 may also comprise a resin dispenser (not shown) or aresin bath or drum (not shown) for applying resin to the filament 46.

In the preferred embodiment, the filament 46 is first wound into thegrooves 42 of the core 20. By way of example only, the filament 46 isstarted in one groove 42 on one side portion 34 of the core 20 and thefilament 46 is wound across the core 20 in a first direction 60. Whenthe filament 46 is wound about the last groove 42 on the opposite sideportion 34 of the core 20, the filament 46 is moved inwardly to continuewinding across the channels 42 in a second direction 62. Those skilledin the art will appreciate that the first and second directions 60, 62can be reversed from those depicted in FIG. 2.

Preferably, filament 46 is repeatedly wound within the grooves 42 asdescribed above until the filament 46 within the grooves 42 issubstantially planar with the front face 26, the upper surface 28 and/orthe lower surface 24. In the preferred embodiment, the same strand ofcontinuous filament 46 is then wound across the front face 26, the uppersurface 28 and the lower surface 24 to substantially cover each of thosesurfaces. The filament 46 is preferably wound across the core 20 fromthe first direction 60 to the second direction 62. The present inventionalso includes winding the filament 46 across the core 20 in any pattern,design or orientation after the grooves 42 have been wound. Thecurvilinear shape of the core 20 may prevent winding the entire core 20in substantially one direction as the filament 46 can slide off one ofthe side portions 34, however, it is preferred to cover each of thesurfaces 26, 28, 24 as much as possible with a uniform layer of filament46.

In the preferred embodiment, the core 20 is wrapped in the continuousstrand of filament 46 to provide a layer of filament 46 above at leastone of the surfaces 24, 26, 28 of the core 20 from approximately onefive thousandths (0.005″) of an inch to one ninety thousandths (0.090″)of an inch.

In another embodiment, the core 20 may be wrapped, e.g., vertically,with additional filament 46 after the initial layer of continuousfilament 46 has been completed. The additional filament 46 may becontinuous or non-continuous and it may be located across the entirecore 20, or only selected portions of the core 20, for example, theends. The additional filament 46 may be of the same material as theinitial layer, or it may be of a different material.

The wound core 20 is then removed from the filament-winding machine 44and located in a mold. A preferred embodiment of a cross-section of amold is depicted in FIG. 3. The mold may be an injection mold, atransfer mold, or a compression mold, as known by those skilled in theart.

In the embodiment depicted in FIG. 3, a transfer mold 64 is shown. Themold 64 has a material reservoir 66 in fluid communication with achamber 68 via at least one channel 70. One or more electric coils 72are located throughout the mold 64 for heating the mold 64, althoughchannels (not shown) for heated oil and/or steam may also be used inconjunction with the electric coils 72 or alone.

A removable insert 74 is located within the chamber 68. The insert 74has a wall 76 having a complementary shape to at least the wound frontface 26 of the core 20. Inserts 74 having walls 76 at various angles,which determines loft in degrees of the club face, and sizes withrespect to the wound front face 26 of the core 20 may be used to locatea face plate 78 at various desired angles.

The present invention also comprises the face plate 78 and a sole plate80, as shown in FIGS. 3 and 4. The face plate 78 and the sole plate 80may be two separate pieces, but preferably, the face place 78 and thesole plate 80 have either been welded together, integrally formedtogether, or otherwise joined. The face plate 78 and the sole plate 80are preferably constructed of a highly wear resistant material, such astitanium, titanium alloys or steel alloys, for instance stainless steel.An outer surface 82 of the face plate 78 may have one or more verticaland/or horizontal grooves 86. The grooves 86 help impart, or decrease,spin to a golf ball depending on groove design.

Face plates 78 and sole plates 80 of various sizes and shapes may beused to create club heads having different appearances. By way ofexample only, a face plate 78 that is slightly larger than the woundcore 20 may be used, or a face plate 78 that is about the same size asthe wound core 20 may be used. In the latter embodiment, the face plate78 will be substantially flush with the finished club head. In theformer embodiment, the face plate 78 will be slightly larger than thefinished club head.

In the preferred embodiment, the face plate 78 and the sole plate 80 arelocated within the mold 64 adjacent the removable insert 74, as shown inFIG. 3. The mold 64 and at least one wall 76 of the insert 74 may bedesigned to securely receive the face plate 78 and/or sole plate 80 toprevent movement of the core during the molding step described below.For example, the mold 64 and wall 76 may have a complementary shape tothe face plate 78 and/or the sole plate 80. Alternatively, it is wellwithin the scope of the present invention to locate one or moremechanical fasteners (not shown), such as screws or pins, into the faceplate 78 and/or sole plate 80 to removably secure the face plate 78 andthe sole plate 80 with the core 20 in the mold 64.

Inside surfaces 84 of the face plate 78 and/or the sole plate 80 may bescored or scuffed, for instance by sand blasting or other known methods,to provide a gripping surface for the molding material described below.

As best seen in FIG. 3, the wound core 20 is located into the chamber 68within the mold 64 where the chamber 68 has a substantiallycomplementary shape to the wound core 20. The core prints 112 on thecore 20 preferably fit into complementary shaped recesses 85 in the mold64 to assist in locating the core 20 in a precise position within themold 64. Preferably, a predetermined gap, or wall stock 88, is leftbetween the wound core 20 and the chamber walls 89.

Weights to satisfy design criteria, i.e., center of gravity, may bepositioned in the core mold and molded in place. The weights, ifrequired, will be secured to the club head by the overmolding stepdescribed below.

Preferably, the wound core 20 is positioned in the chamber 68 so that itis approximately half above and approximately half below the channel 70.The channel 70 functions as a gate, as known by those skilled in theart. Those skilled in the art will appreciate that the core 20 can belocated in the chamber 68 in any position, angle or orientation withrespect to the channel 70.

One or more spacers 90 may also be located between the face plate 78 andthe sole plate 80 and the wound core 20. The spacers 90 may be of anyshape, size or dimension. In one embodiment, the spacers 90 are T-shaped(not shown) to provide a large surface area with which molding material,described below, comes in contact. The spacers 90 may have a knurled, orrough, outer surface to assist them becoming secured within a resin,described below.

The spacers 90 may be used to provide, i.e., control the thickness of,the wall stock 88 between the face plate 78, the sole plate 80 and thewound core 20.

As shown in FIG. 5, at least one aperture 92 is located in the faceplate 78 and at least one aperture 94 is located in the sole plate 80.The apertures 92, 94 may be created when the face plate 78 and the soleplate 80 are formed, or the apertures 92, 94 may be located in theplates 78, 80 after formation, such as by drilling. A tube 96 ispreferably located through the apertures 92, 94 in the face plate 78 andthe sole plate 80 and secured by a press fit or friction fit, adhesive,brazing and/or welding. The apertures 92, 94 in the face plate 78 andthe sole plate 80 are preferably located and aligned so that the tube96, when inserted in the apertures 92, 94, is positioned adjacent thedepression 40 in the core 20 for the shaft.

Referring now back to FIG. 3, a pre-determined quantity of athermosetting-engineered resin 98 that is compatible with carbon fibers,e.g., epoxy or polyester resins, preferably epoxies, is located in thereservoir 66 of the mold 64. A thermoplastic-engineered resin that iscompatible with carbon fibers may also be used. In the event athermoplastic resin is employed, provision is made to cool the mold toeffect cure of the resin.

Preferably, non-continuous filaments 100 of carbon and/or Kevlar®, orfilaments 100 having specified physical and performance characteristics,are equally distributed and suspended within the resin 98. The resin 98may be comprised of approximately 20% to approximately 70% filaments100, but preferably the resin 98 is comprised of approximately 50%filaments 100.

The thermosetting resin 98 may be liquefied before being located in thereservoir 66, or it may be liquefied within the reservoir 66. Thevarious resins 98 which may be used with the present invention have aliquefying point between 200 degrees Fahrenheit and 400 degreesFahrenheit. Typically, the mold 64 is approximately 300 degreesFahrenheit to 400 degrees Fahrenheit, so if the resin 98 is notliquefied before entering the reservoir 66, it will quickly becomeliquefied. In either case, the liquefied resin 98 is urged out of thereservoir 66 by any known means, including but not limited to, a pump,and/or a plunger 102. The plunger 102 may be driven by a clamping devicesuch as a hydraulic press holding the two halves of the mold 64 closedtogether.

Those skilled in the art will also appreciate that an injection typemold can also be used without departing from the scope of the presentinvention. In an injection type mold (not shown), a rotating helicalmixing device is located within the reservoir. The helical mixingdevice, when rotating, will decrease the length of any carbon and/orKevlar® filaments within the resin.

In comparison, the transfer type mold 64 described and depicted hereindoes not have a mixing device so that the filaments 100 in the resin 98retain their original length. Therefore, depending on the desiredfilament 100 length in the resin 98, either the injection type mold orthe transfer type mold may be interchangeably used with the presentinvention.

The liquefied resin 98 flows under pressure from the reservoir 66 andthrough the channel 70, as through a gate as known by those skilled inthe art. As described above, the wound core 20 is located within themold 64 so that approximately half of the wound core 20 is located abovethe channel 70 and approximately half of the wound core is located belowthe channel 70. The liquefied resin 98 flows in substantially equalquantities around the wound core 20 in the wall stock 88 about the woundcore 20. The resin 98 also flows around the inserts 30.

The liquefied resin 98 flows through the wall stock 88 to overmold thewound core 20. The pressurized resin 98 flows into any voids not filledby the continuous filament 46 on the core 20 and it permeates throughthe filament 46 located over the upper surface 28, the lower surface 24,the filament 46 over the front face 26 and the filament 46 in thegrooves 42. The resin 98 is also located in the wall stock 88 betweenthe wound core 20 and the face plate 78 and the sole plate 80 andbetween the tube 96 and the wound core 20.

A fiber filled resin coating (or an unfilled pure resin in circumstanceswhere the resin is used for an improved surface finish) over the woundcore 20 having a thickness of between approximately one five thousandths(0.005″) of an inch to approximately one ninety thousandths (0.090″) ofan inch is desirable.

The resin 98 is allowed to cure under heat and pressure in the mold 64for a pre-determined amount of time. Once the resin 98 is sufficientlycured, the overmolded core 20, now having the face plate 78, the soleplate 80 and the inserts 30 secured thereto and the tube 96 securedtherein, referred hereinafter as the club head 104, is removed from themold 64. An outer surface 106 of the club head 104 that was locatedadjacent the mold chamber walls 89 now has a surface dependent on fibercontent. For example, the surface can be smooth, as shown in FIG. 6, orvariegated.

Those skilled in the art will also appreciate that the walls 89 of thechamber 68 can be provided with any surface to provide a smooth outersurface 106 of the club head 104 or the walls 89 can be designed tocreate any design or pattern on the outer surface 106 of the club head104. By way of example only, the walls 89 of the chamber 68 can bedesigned to create a leather-like or wood-like appearance on the outersurface 106 of the club head 104, or they can be designed to create anon-reflective surface on the outer surface 106 of the club head 104.

In any event, with a soluble core of the type described in U.S. Pat. No.3,692,551, in the molded plastic club head 104, the core material/bindercan be quite readily removed from the club head with water. For example,with a core 20 in which both the hardened salt binder and skin are watersoluble, the head 104 with the core 20 is placed in a bath of water in acontainer or tank and a stream of water employed, with the bath, todissolve the binder and flush the core material from the head 104. Withthis procedure, the shape of the core 20 is destroyed within the head104 and the destruction product or core material dispersed therefrom.

The liquid/solvent can directly contact the core 20 through a hole 107.The hole 107 was created during the above-described molding step as theresin 98 flowed around the insert 30 containing the core prints 112.Those skilled in the art will appreciate that one or more holes 107 maybe located in the club head 104, such as, for example, by drilling. Thedissolved binder and core material can be poured out from the club head104, as shown in FIG. 7.

FIG. 8 schematically depicts a cut away view of the club head 104 withthe core 20 removed and an insert 30 located in the club head 104. Theovermolded continuous filament 46 in the walls 108 and ribs 110 formedby the grooves 42 of the club head 104 can be seen. Individual pieces offilament 100 can also be seen in the walls 108 of the club head 104.

FIG. 9 depicts the club head 104 with two molded in inserts 30. Thoseskilled in the art will appreciate that the inserts 30 can also bethreaded into place and/or an adhesive or cement can be used.

Plugs 114, having a set of complementary threads to the threaded inserts30, are threaded into the inserts 30. The plugs 114 cover the hollowinserts 30 and they can also be weighted to customize the weight of theclub head 104. The plugs 114 can be equally weighted or they can havedifferent weights. Channels 118 within the heads of the plugs 114 have acomplementary design to a Phillips head screwdriver, standard headscrewdriver, or hex wrench so the plugs 114 can be readily inserted orremoved.

Those skilled in the art will appreciate that instead of, or in additionto, locating the weights as described above, the club head 104 can bedrilled and inserts 30 and plugs 114 can be inserted in the holes, orweighted inserts can be molded into the core at selected areas.

A golf club head shaft 120 is frictionally and/or adhesively attachedthrough a shaft locator aperture 122 in the face plate 78 and into theclub head 104, as shown in FIG. 10. Within the club head 104, the shaft120 is located within the tube 96 and secured thereto with frictionand/or an adhesive as known to those skilled in the art.

The golf club head 104 assembled according to the steps described aboverobustly supports the face plate 78 to reduce, or prevent, deflection ofthe face plate 78 upon contact with a golf ball. Reducing, orpreventing, deflection of the face plate 78 decreases energy absorptioninto the golf club head 104 and concentrates energy to the golf ball.Additionally, it can be appreciated that golf club heads 104 madeaccording to the steps described herein may have different appearancesthan the preferred embodiment depicted in FIG. 10. For instance, thewalls 108, the face plate 78 and the sole plate 80 of the club head 104may have any shape or size in accordance with United States GolfAssociation standards.

In accordance with the provisions of the patent statutes, the presentinvention has been described in what is considered to represent itspreferred embodiments. However, it should be noted that the inventioncan be practiced otherwise than as specifically illustrated anddescribed without departing from its spirit or scope.

1. A golf club head, comprising a shell having an inside surface and anoutside surface, said inside surface defining a substantially hollowinterior portion of said shell and wherein said inside surface has aplurality of inwardly extending ribs, wherein said ribs and said shellbeing substantially comprised of a resin and a single continuousfilament located within said resin.